KR20010042675A - Multi-ply food container - Google Patents

Abstract

The food container 10 of the present invention comprises three or more layers, namely a first layer 22, a second layer 24 and at least a third layer 26. The first layer 22 is oriented towards the user's hand and face and, in use, houses the food. The second layer 24 is a space that separates the first layer 22 and the third layer 26. In a preferred embodiment, the food container 10 may be made of corrugated material. Food containers may be made of blanks whose planes may be deformed during manufacture.

Description

Multi-layer food container and manufacturing method thereof {MULTI-PLY FOOD CONTAINER}

Disposable food containers are known in the art. Disposable food containers include conventional paper plates, air, clams, trays and the like.

The present technology relates to the manufacture, molding and deformation of these food containers in a single plane. In this latter method blanks are provided. The blank is inserted and compressed between the engagement platens. The blank may have radial grooves on its outer circumferential surface. Radial grooves are provided for the accumulation of material deformed by the platen. Exemplary techniques include U.S. Patent No. 3,033,434 to Carson, May 8, 1962, U.S. Patent 4,026,458 to Morris et al., May 31, 1977, and Max. US Patent No. 4,606,496, US Patent No. 4,609,140 to Van Handel et al. On September 2, 1986, US Patent No. 4,721,500 to Van Handel et al. On January 26, 1988, U.S. Patent No. 5,230,939, issued July 27, 1993 to Baum, and U.S. Patent No. 5,326,020, issued July 5, 1994 to Cheshire et al., Which are incorporated herein by reference. Homogeneity aids in radially symmetrical deformation of round food containers such as dishes and air.

The blank is usually constructed of cardboard, in particular of a single sheet of cardboard, as disclosed in the above-mentioned patent. A single sheet of cardboard is used because of the belief that the blank is thin and monolayer to deform the blank in plane. The cardboard or other material used for the blank is typically substantially homogeneous, as disclosed in US Pat. No. 4,721,499, issued Jan. 26, 1988 to Max et al. Homogeneity aids in radially symmetrical deformation of round food containers such as dishes and air.

However, these in the art have some disadvantages. As illustrated by excessive attempts to improve the strength and stability of food containers, prior art attempts do not provide food containers of sufficient strength. This weak strength may result in excessive spillage of the food, or inadequately suppresses the amount of food that may be placed in the food container after a predetermined time.

There is another disadvantage with the prior art single layer cardboard food containers. Relatively thin single layer cardboard is only minimally insulated. When warm food is placed on the food container, there is little insulation and the food is cooled. This cooling occurs because heat is transferred through the food container to its bottom side or to the atmosphere.

Accordingly, there is a need in the art to provide food containers that provide increased strength, stiffness and thermal insulation. One optimal solution is to increase the thickness of the blank. However, this increase in thickness inevitably increases the material cost because the material cost is proportional to the basis weight of the blank.

Thus, there is a need in the art for food containers having the properties described above but without the undesirable material cost. Moreover, the blanks for such food containers must be easily deformed in the plane.

One attempt in the art to overcome this compromise is to use multilayer laminate food containers. For example, it is known in the art to make food containers from corrugated laminates. Such food containers typically have panels cut and folded, as disclosed in US Pat. No. 5,205,476, issued April 27, 1993 to Surrenson. However, such cut and folded food containers require expensive folding devices and are inherently unreliable. Adjacent panels in food containers are defined by cutouts or cutouts. After adjacent panels are folded together, these panels must be glued or mechanically interlocked to hold them in place. Adhesives and their associated application devices require additional equipment and processing material costs. The mechanical material has a tab. Tabs require cutting / dividing operations and are not inherently reliable. The tabs are separated, torn or simply misaligned.

One attempt in the art to address this drawback uses a single-sided corrugated material and cuts and cuts food containers as disclosed in U.S. Patent No. 5,577,989 to Neary, Nov. 26, 1996. Use continuous forms rather than folds. The continuously formed food container has a peripheral portion that is progressively and continuously raised through the transition area with respect to the central area of the food container. However, single-sided corrugated materials do not have strength or do not have the thermal insulation performance of three layer corrugated materials. It is known in the industry that it is not possible to stamp two or more layers of corrugated cardboard to form a satisfactory single structure as disclosed in US Pat. No. 5,577,989.

However, these deficiencies of the prior art are overcome by the present invention. The present invention provides, in one embodiment, a multi-planar food container made from a three layer corrugated material without resorting to prior art cutting, cutting and folding techniques.

Summary of the Invention

The present invention includes a multilayer food container having an XY plane and a Z direction orthogonal to the plane. The multilayer food container comprises at least three layers, namely a first layer, a second layer and a third layer. The second layer is interposed between the first layer and the third layer, and the first layer and the second layer are spaced apart from each other by the second layer. The second layer provides an air space between the first layer and the second layer. The air space helps to reduce heat transfer through the food container. The food container is multi-sided and has first and second portions spaced in the Z direction. The spaced first and second portions are connected by successive transition regions.

In a preferred embodiment, the second layer comprises corrugated media. However, it should be appreciated that all embodiments that provide individual, semi-continuous or continuous space in the second layer and that separate the first and third layers may be suitable for the present invention.

The present invention relates to a food container of the present invention, in particular a food container which may be disposable, and more particularly to a food container including multiple layers.

1 is a perspective view of one embodiment of a food container according to the present invention;

2A is a vertical cross-sectional view taken along line 2A-2A of FIG. 1;

FIG. 2B is a partial enlarged view of portion 2B of FIG. 2A;

Fig. 3 is a plan view of the shim used in the present invention in which the food container is partially cut to show the wrinkles of the second layer, and superimposed on the food container.

1 and 2A, the food container 10 according to the present invention comprises a dish, air, a tray, a clamshell or any other shape known in the art.

The food container 10 includes a central region 14 and a peripheral outer circumferential surface 16. The central region 14 and the outer circumferential surface 16 are arranged in two different planes. The central region defines the XY plane of the food container 10. The Z direction of the food container 10 is perpendicular to the XY plane. The food container 10 needs to have a transition region 20 from the central region 14 to the outer circumferential surface 16. In normal use, the outer circumferential surface 16 is typically raised relative to the central region 14.

The food container 10 includes three layers, namely a first layer 22, a second layer 24 and a third layer 26. The second layer 24 spaces the first layer 22 and the third layer 26 in the Z direction.

Either the central region 14 or the outer circumferential surface 16 need not be parallel to the XY plane or generally a plane. For example, air with a generally concave bottom may be suitable for use in the present invention. Only the central region 14 and the outer circumferential surface 16 need be spaced apart in the Z direction. The Z direction distance from the bottom surface of the central region 14 (which is taken while the food container 10 is in normal use and generally in a horizontal position) to the top surface of the outer circumferential surface 16 is determined by It can be regarded as Z direction depth 19. If the depths of the different portions of the food container 10 are different, the Z direction depth can be taken as the largest Z direction distance.

The boundary and shape of the outer circumferential surface 16 is defined by the edge 18 of the food container 10. The dimensions and relative proportions of the outer circumferential surface 16 and the central region 14 of the food container 10 may vary depending on the exact size of the food container 10 and the intended use. Although a round food container 10 is shown in FIG. 1, those skilled in the art can understand that any suitable shape and depth of the food container 10 can be selected for use in the present invention, and the present invention is not limited to this. have. Other suitable shapes include squares, rectangles, ovals, various polygons, and the like.

The food container 10 according to the invention can be made of any rigid material, in particular a material provided for use in storing, cooking, dispensing and eating food from the container. The food container 10 may be made of cellulose, such as solid bleached sulfite cardboard and various types of wood fibers, including recycled fibers. Optionally, suitable rigid materials for food container 10 include foam, plastic, and other synthetic materials and aluminum foil.

Those skilled in the art will appreciate that the first, second and third layers 22, 24, 26 may be made of the same material. The first layer 22 needs to be hygienic and preferably aesthetically pleasing to the consumer, but the second and third layers 24, 26 need not be. The second and third layers 24 and 26 may be selected for strength, aesthetics and cost savings.

If desired, one or more of the layers 22, 24, 26 may be treated with a reinforcing material, as known in the art. If only one of the layers 22, 24 or 26 is treated for strength, then the layer to be treated is the second layer 24. The second layer 24 may have increased strength because the second layer 24 carries the compressive and bending loads applied to the food container 10.

For example, the second layer 24 can be treated with epoxy or other synthetic resin as known in the art. Additionally or alternatively, the second layer 24 may be treated or penetrated with lignin as known in the art. Those skilled in the art will appreciate that various other means may be used to reinforce one or more of the layers 22, 24, 26 as is known in the art. For example, radial reinforcement ribs (not shown) are applied to the bottom surface of the food container 10 and bonded to the third layer 26. This reinforcing rib distributes the load applied towards the edge 18 of the food container 10 near the center of the food container 10.

As shown in FIGS. 1 and 2A, the food container 10 is multi-planar. Multiplanar means that different portions of the food container 10 can be placed in different planes. An example of multiple planes of the food container 10 of the present invention is shown by the central region 14 and the outer circumferential surface 16 of the food container 10. The central region 14 and the outer circumferential surface 16 of the food container 10 are spaced apart in the Z direction, thereby making the food container 10 multi-planar. As mentioned above, the outer circumferential surface 16 may be raised relative to the central region 14 while the food container 10 is in use, but is not limited thereto.

Occasionally, the difference in the Z-direction height of the food container 10 will be a function of the radial position within the food container 10. However, the present invention is not limited to this. The difference in Z direction height will also be a function of the circumferential position on the food container 10. The invention is not limited to an axisymmetric food container 10 or a food container 10 that is symmetric about all particular planes.

The multi-planar food container 10 has at least one continuous transition region 20 between different portions of the food container 10 spaced in the Z direction. By "continuous transition region 20" it is meant that deflection or correction in the Z direction can be made without folds, cuts, cut lines or perforations. In the sense of the plane, the absence of fold lines, cutouts, cutouts or perforations means that there is no convex portion in which the height of the food container 10 changes in the Z direction. The convex portion may be any point in the cross section where there is a separation, rather than a continuous change in height in the Z direction. In the embodiment shown in the figures, the change in the Z direction height will be a function of the radial position in the food container 10.

It is necessary to accommodate the accumulation of material that may occur when the food container 10 has one or more continuous transition regions 20. Pleats or wrinkles are often used for this purpose. Pleats and pleats, particularly accumulated pleats in radial orientation, are envisaged and are within the scope of the present invention. These pleats and wrinkles intersect the transition region 20 and do not interfere with the requirements or provisions of the continuous transition region 20.

The accumulated pleats described above do not form part of the Z-direction space. The accumulation pleat simply prevents the formation of multiple thicknesses of corrugated media at corners adjacent to the folds and the like. These multiple thicknesses of material appear to be excessive use of the material, thus increasing the cost of the food container 10. A particularly characteristic feature of the preferred embodiment of the food container 10 according to the present invention is that it is bonded or otherwise joined together to form part of the Z-direction space of the present invention without overlapping flaps or panels.

The Z-direction space of the present invention is provided by the continuous transition region 20. Continuous transition areas eliminate the need for fold lines, cut lines, cutouts or perforations, but they pleat or fold in the prior art to provide a constant, spaced crease point for excess material when the food container 10 is formed. It can be provided strictly as an auxiliary feature as in. Prior art pleats and corrugations accommodate modified material during the manufacturing process but do not affect the transition between different Z-direction heights of different portions of the food container.

These pleats and wrinkles typically cross the transition region 20. In contrast, the prior art cuts, cut lines and fold lines are parallel to the transition region 20. The cutout, cutout and fold line are not in the food container 10 of the present invention.

The continuous transition region 20 of the present invention is curved in cross section. While the continuous transition region 20 of the curve has a radius of curvature of at least 5 mm, the suitable transition region 20 may have a radius of curvature of 1 to 25 mm. Preferred curvature radius is 1 to 10 mm. This radius of curvature is measured on the outward surface of the first layer 22.

2A and 2B, food container 10 includes a multilayer stack. Preferably, the laminate comprises three layers, namely first layer 22, second layer 24 and third layer 26. However, structures of three or more layers are possible within the scope of the present invention. The first and third layers 22, 26 are outer layers, which face and form the outwardly facing surface of the food container 10. The second layer 24 is inserted between the first layer 22 and the third layer 26.

In the embodiment shown and described in the figures, the first layer 22 and the third layer 26 have a smooth surface. The first layer 22 faces the user, upon which the food is placed. The third layer 26 may be formed with condensation to reduce slip during use. Smooth means that the first layer 22 and the third layer 26 are macroscopically continuous in the XY plane and not coarse on contact.

The first layer 22 allows for easy removal of food during eating or heating and other cooking and storage. The third layer 26 allows the food container 10 to be conveniently held in one hand, wrap, or table. The first layer 22 and / or the third layer 26 may be printed or coated. Printing can provide a display. The coating can provide a hygienic or moisture impermeable eating surface.

The second layer 24 is discontinuously coupled to at least one of the first layer 22 or the third layer 26, and spaces the first and third layers 22, 26 from each other in the Z direction. The second layer 24 thereby allows air or other insulating material such as foam to be interposed in the first layer 22 and the third layer 26.

The second layer 24 can include any configuration that separates the first and third layers 22, 26 in the Z direction into discontinuities therebetween. For example, the second layer 24 may include a series of spacers that can be spaced apart from each other individually in the XY plane. In addition, the spacer comprising the second ply 24 is semi-continuous, ie extends substantially in one direction in the XY plane. In addition, a honeycomb material may be used for the second layer 24.

Spacers, honeycomb materials and the like prevent the first and third layers 22, 26 from contacting each other throughout the XY plane. Thus, the first and third layers 22, 26 are only connected to each other at the position where the spacers are joined to the first and third layers 22, 26. The spacer may be adhesively bonded to the opposingly disposed first and third layers 22, 26, and the first and second layers 22, 26 depending on the choice of material used in the construction of the layers 22, 26. Heat seal).

Preferably, food container 10 comprises a corrugated configuration as is known in the art. The corrugated configuration includes first or third outer layers 22, 26 and a corrugated layer 24 therebetween. The corrugated layer 24 is not bonded at all locations to the outer layers 22, 26, but instead has a corrugation 32 comprising grooves and ribs spaced apart from the flat layers 22, 26. Ribs and grooves are often straight and parallel. In cross section, the ribs may be S-shaped, C-shaped, Z-shaped, or any other shape known in the art. Suitable corrugated materials are A to N size grooves, with E to N size grooves being preferred. Particularly preferred corrugated media include corrugated grooves. The corrugated groove pleat medium has a pleat 32 having a vector component parallel to both the X and Y directions. This configuration provides a laminate having more nearly uniform properties in the X and Y directions. In particular, the hollow corrugated groove pleated medium has a pleat 32 close to a sinusoidal pattern.

The corrugated laminate comprising all three layers 22, 24, 26 may have a combined basis weight of 100 to 1,000 grams per square meter, with a basis weight of 125 to 700 grams per square meter. The corrugated material represents a preferred embodiment of the present invention but has a spaced apart first layer 22 and a third layer 26 and a first layer 22 for storing and dispensing food. It is to be understood that all configurations of one or more layers 22, 24, 26 may be suitable.

The food container 10 may be formed by providing a multilayer blank as described above. The multilayer blank deforms out of plane by engaging the platen as is known in the art. Exemplary devices suitable for transforming a blank into a three-dimensional food container 10 include US Pat. No. 2,832,522 to Schranzer on April 29, 1958, and US Pat. US Pat. No. 2,997,927, US Pat. No. 3,033,434 to Carson on May 8, 1962, US Pat. No. 3,305,434 to Vernier et al. On February 21, 1967, and May 31, 1977 US Patent No. 4,026,458 to Morris et al., Which is incorporated herein by reference.

The engagement platen performs the task of deforming the multilayer blank in the Z direction beyond the XY plane. The platen fixes both blanks and performs all of the functions of deforming the blank in the Z direction. Preferably, the blanks weakly fix their edges 18 corresponding to the outer circumferential surface 16 of the food container 10. When the platen engages and secures the multilayer blank in the Z direction, the outer circumferential surface 16 will slide through the platen due to the weak holding force described above. This slippage causes the blank to deform in the Z direction, thereby preventing the blank from undesirably deforming.

Importantly, in the method according to the invention for producing the food container 10, the engagement platen deforms the blank in the Z direction without adding moisture. Adding moisture above the moisture present in the atmosphere tends to cause tearing on the tension layer of the blank due to deformation in the Z direction. Thus, the process according to the invention is carried out without the addition of moisture as opposed to the techniques of the prior art, as disclosed, for example, in U.S. Patent No. 5,557,989 to Nearer, above.

A gap may be provided between the engagement platens such that there is no compressive load applied to the central region 14 of the food container 10. However, the outer circumferential surface 16 and other portions of the food container 10 may be subjected to compressive loads, in particular eccentric compression loads, for deformation and reinforcement.

Referring to Figure 3, the engagement platen may be edged to prevent undesirable compression of the blank if necessary. The rim allows compression into areas of the blank with it, preventing undesirable compression on other parts of the blank. If the second layer 24 has an orientation characteristic as occurs in the corrugated material, the rim 50 may be eccentrically oriented in an azimuth pattern that accommodates the orientation characteristic of the second layer 24. Surprisingly, the major axis of the rim 50 should be parallel to the major axis of the pleats of the second layer 24.

This configuration makes the portion of the outer circumferential surface 16 embedded in the rim more compact than the central region 14. Thus, the central region 14 may be thicker than the inherent portion of the outer circumferential surface 16.

The thickness of the rim 50 is from about 25% to about 75%, preferably from about 30% to 50% of the thickness of the blank before deformation by the engagement platen. The rim 50 may taper to a smaller thickness at its end or at its inner diameter.

The rim 50 may be disposed on a sector of the round food container 10. The sector may be embedded in an arc of 60 ° to 120 °, preferably about 90 °, of the round food container 10, or one quadrant. If this configuration is chosen, the edges 50 can be oppositely opposite.

In another preferred embodiment, the platen of the mold may be provided with an eccentric sidewall gap. The sidewall gap perpendicular to the rib of the crease 32 is larger than the sidewall gap parallel to the rib of the crease 32. Again, the eccentric will change continuously and gradually between the adjacent 90 ° quadrants of the mold platen with respect to the round food container 10. In the embodiments described herein, if the three-layer laminate corrugated material has a basis weight of 100 to 1,000 grams per square meter, the gap is from a minimum of about 0.01 to about 0.05 inches to a maximum of about 0.03 to about 0.09 inches. It can vary.

If desired, the laminate forming the food container 10 may be sealed. Sealed means that the space between the first layer 22 and the third layer 26 is sealed at the edge 18 of the food container 10. Sealing the stack prevents or reduces convective electricity between the first layer 22 and the third layer 26. By preventing or reducing convective current, heat loss is reduced, and by sealing the edge 18, the thermal insulation performance of the food container 10 is improved. In addition, depending on the material used for sealing, the strength and rigidity of the food container 10 may be improved. Furthermore, sealing the edges 18 of the food container 10 can improve aesthetic appearance and hygiene.

Sealing the edge 18 of the food container 10 adds individual strips of material by contact bonding to the edge 18, securing the first and third layers 22, 26 together at the edge 18 and This may be accomplished by immersing the edge 18 in wax, painting thick paint on the edge 18, or using other known filler and seal materials that are applied in any suitable manner.

If desired, the three layers 22, 24, 26 may be provided separately rather than as a single stack. The three layers 22, 24, 26 can be joined together in the same way to transform the blank into a multilayer food container 10. This method performs the dual function of combining the layers 22, 24, 26 in a single operation and deforming the multilayer food container 10 in the Z direction.

This method may be performed as follows, the second layer 24 may be an adhesive applied to the portion of the second layer 24 that contacts the first and third layers 22, 26. For example, if the corrugated material is selected for the second layer 24, the top of the rib of the corrugation 32 can be applied with an adhesive. The adhesive may be applied by printing on top of the ribs of the pleats 32 as is known in the art. Of course, it is not necessary to apply an adhesive to each of the wrinkles 32. For example, the adhesive may be applied according to the lamination strength required for the end use where only optional wrinkles 32 or peripheral wrinkles 32 are needed. Optionally, the inner surfaces of the first and third layers 22, 26 may be applied with an adhesive. Suitable adhesives are pressure sensitive and starch based adhesives.

In other embodiments, the inner surfaces of the first and third layers 22, 26 or the tops of the ribs of the pleats 32 of the second layer 24 may be covered with a polymer film. Next, the first, second and third layers 22, 24 and 26 are joined together by heat sealing.

Next, the three layers 22, 24, 26 are compressed by the platen as described above. Compression from the platen results in joining the three layers 22, 24, 26 and deforming the final stack into a multilayer food container 10. Optionally, it is not necessary to provide separate adhesives to join the three layers 22, 24, 26 together. By way of example, native adhesion or edge crimping may be used.

Optionally, the first layer 22 or the third layer 26 may be provided separately from the other two layers. The other two layers are provided joined together. Next, the three layers 22, 24, 26 are compressed by the platen and all three layers 22, 24, 26 are joined together at the same time.

If desired, laminates of three or more layers 22, 24, 26 may be used. For example, a five layer food container 10 having three smooth layered crimps with two corrugated layers interposed therebetween may be used. This configuration provides a food container 10 thicker than the three compressible layers 22, 24, 26. If this configuration is chosen, the pleats 32 of the two pleated layers need not be identical. The wrinkles may be different in size.

The different corrugated layers may have straight portions and / or corrugated grooves in the corrugations. Optionally, the intermediate layer spacing the smooth layer can be a combination of corrugated material, honeycomb, individual spacers, and the like. Those skilled in the art can understand various other configurations.

Claims (10)

In a multy-ply food container having an XY plane and a Z direction orthogonal thereto, The multilayer food container includes an outer circumferential surface and a central region, each of the outer circumferential surface and the central region having a thickness portion and spaced apart in the Z direction, wherein the thickness portion of the central region is larger than the thickness portion of the outer circumferential surface, the multiple The layer food container comprises three layers, namely a first layer, an inner second layer and a third layer, wherein the second layer is interposed between the first layer and the third layer, whereby the first layer And the third layer is spaced apart from each other, the second layer provides an air space between the first layer and the third layer, and the food container is multi-plane and spaced in the Z direction. A portion, wherein the first and second portions are joined by a continuous transition region. Multilayer Food Container. In a multilayer food container having an XY plane and a Z direction orthogonal thereto, And at least three layers, wherein the food container includes an outer circumferential surface and a central region spaced in the Z direction, each of the outer circumferential surface and the central region having a thickness portion and the thickness portion of the central region having a thickness thicker than the outer circumferential surface; A corrugated laminate, the corrugated laminate having at least one smooth outer layer and an inner layer bonded thereto, the inner layer comprising a corrugated medium, the food container being multi-planar, Z Directionally spaced first and second portions, the first and second portions being joined by a continuous transition region. Multilayer Food Container. In a multilayer food container having an XY plane and a Z direction orthogonal thereto, The food container includes at least three layers, the food container including a corrugated laminate, the corrugated laminate forming a central region of the food container spaced in a Z direction from a peripheral circumferential surface and the outer peripheral surface. Thicker, the central region having two smooth outer layers and an inner layer between these layers, the inner layer comprising a spacer, the spacers being spaced apart from each other in the XY plane, the first layer and The third layer is coupled to the spacer such that the first layer and the third layer are disposed on opposite sides of the food container in the Z direction, the food container being multi-plane and spaced in the Z direction. And a second portion, wherein the first and second portions are joined by a continuous transition region. Multilayer Food Container. A multi-layer food container having a central region and an outer circumferential surface region adjacent thereto, The central region is thicker than the outer circumferential surface region, the outer circumferential surface region is displaced from the central region in the Z direction, and the central region and the outer circumferential surface region are coupled to each other without a fold line therebetween, whereby The transition portion joins the central region and the outer peripheral surface region Multilayer Food Container. The method according to any one of claims 1 to 3, The continuous transition region is free of creases, tear lines, cutouts or perforations. Multilayer Food Container. The method according to any one of claims 1 to 3 or 5, The second layer comprises a corrugated grooved corrugated medium Multilayer Food Container. A method of making a multilayer food container, Providing a multilayer blank having a XY plane and a Z direction orthogonal thereto, the multilayer blank comprising at least three layers, i.e., a first layer, a second layer, and a third layer, wherein the second layer is in contact with the first layer. Providing said multilayer blank, interposed between said third layers and separating them to provide an air space therebetween; Providing a pair of engagement platens, one of which can be moved in the Z direction relative to the other; Interposing the blank between the engagement platens; Moving the platens together in the Z direction to compress at least a portion of the blank, thereby forming a multi-layer food container having an outer circumferential surface adjacent to the central area, thicker than the central area, and spaced in the Z direction. And wherein said outer circumferential surface in said central region is joined by a continuous transition region. Multi-layer food container manufacturing method. The method of claim 7, wherein The step of forming the multilayer container comprises eccentrically compressing an outer circumferential surface of the food container Multi-layer food container manufacturing method. The method of claim 8, Wherein the second layer comprises a pleat, wherein the eccentric compression is in an azimuth pattern, and is about a major axis parallel to the pleat Multi-layer food container manufacturing method. A method of making a multilayer food container, Providing three layers, namely a first layer, a second layer and a third layer, each of the layers having a XY plane and a Z direction orthogonal thereto, wherein the second layer comprises the first layer and the first layer Interposed between the three layers, thereby separating the first layer and the third layer, providing an air space between the first layer and the third layer, wherein at least two of the adjacent layers are not joined together Providing the three layers, Disposing the first layer, the second layer and the third layer in a face-to-face relationship, whereby the layers are in contact and the second layer separates the first layer from the third layer; The batching step, Providing a pair of engagement platens, one of which may be moved in the Z direction relative to the other, wherein the three layers are interposed between the engagement platens; The platens are moved together in the Z direction to compress at least a portion of the three layers together, thereby joining the three layers into a monolithic stack, having first and second portions spaced in the Z direction and continuous Forming a multi-layer food container bound by conventional transition regions; Multi-layer food container manufacturing method.